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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1979

Reactions of calcium orthosilicate and barium zirconate with oxides and sulfates of various elements

Calcium orthosilicate and barium zirconate were evaluated as the insulation layer of thermal barrier coatings for air cooled gas turbine components. Their reactions with various oxides and sulfates were studied at 1100 C and 1300 C for times ranging up to 400 and 200 hours, respectively. These oxides and sulfates represent potential impurities or additives in gas turbine fuels and in turbine combustion air, as well as elements of potential bond coat alloys. The phase compositions of the reaction products were determined by X-ray diffraction analysis. BaZrO3 and 2CaO-SiO2 both reacted with P2O5, V2O5, Cr2O3, Al2O3, and SiO2. In addition, 2CaO-SiO2 reacted with Na2O, BaO, MgO, and CoO and BaZrO3 reacted with Fe2O3.

Zaplatynsky, I.↗
NASA NTRS1985

Thermal expansion mismatch and oxidation in thermal barrier coatings

Thermal barrier coatings (TBC) for advanced gas turbine blades have been under intensive development during the last several years. This investigation is intended to achieve a clearer understanding of the mechanical behavior of plasma sprayed zirconia-yttria TBCs, involving a nickle-chromium-aluminum bond coat. The near term objectives are to study the stress states in a relatively simple model TBC subjected to steady state thermal loading. The resulting thermal expansion mismatch and oxidation have been primary targets for the study. The finite element approach and the effects of thermal mismatch and oxidation are described. A proposed mechanism for oxidation induced coating failure is also presented.

Chang, G. C.↗
NASA NTRS1989

Thermal barrier coating life prediction model development, phase 1

The objective of this program was to establish a methodology to predict thermal barrier coating (TBC) life on gas turbine engine components. The approach involved experimental life measurement coupled with analytical modeling of relevant degradation modes. Evaluation of experimental and flight service components indicate the predominant failure mode to be thermomechanical spallation of the ceramic coating layer resulting from propagation of a dominant near interface crack. Examination of fractionally exposed specimens indicated that dominant crack formation results from progressive structural damage in the form of subcritical microcrack link-up. Tests conducted to isolate important life drivers have shown MCrAlY oxidation to significantly affect the rate of damage accumulation. Mechanical property testing has shown the plasma deposited ceramic to exhibit a non-linear stress-strain response, creep and fatigue. The fatigue based life prediction model developed accounts for the unusual ceramic behavior and also incorporates an experimentally determined oxide rate model. The model predicts the growth of this oxide scale to influence the intensity of the mechanic driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads.

Demasi, Jeanine T.↗
NASA NTRS1994

Quality optimization of thermally sprayed coatings produced by the JP-5000 (HVOF) gun using mathematical modeling

Currently, thermal barrier coatings (TBC) of gas-turbine blades and similar applications have centered around the use of zirconia as a protective coating for high thermal applications. The advantages of zirconia include low thermal conductivity and good thermal shock resistance. Thermally sprayed tungsten carbide hardface coatings are used for a wide range of applications spanning both the aerospace and other industrial markets. Major aircraft engine manufacturers and repair facilities use hardface coatings for original engine manufacture (OEM), as well as in the overhaul of critical engine components. The principle function of these coatings is to resist severe wear environments for such wear mechanisms as abrasion, adhesion, fretting, and erosion. The (JP-5000) thermal spray gun is the most advanced in the High Velocity Oxygen Fuel (HVOF) systems. Recently, it has received considerable attention because of its relative low cost and its production of quality coatings that challenge the very successful but yet very expensive Vacuum Plasma Spraying (VPS) system. The quality of thermal spray coatings is enhanced as porosity, oxidation, residual stress, and surface roughness are reduced or minimized. Higher densification, interfacial bonding strength, hardness and wear resistance of coating are desirable features for quality improvement.

Tawfik, Hazem↗
NASA NTRS1995

Influence of Two-Phase Thermocapillary Flow on Liquid Retention in Microscopic Pores

An important feature of screened propellant acquisition devices is the retention capability or maximum maintainable pressure difference across the porous barrier separating the liquid and gas. Previous experiments with liquid hydrogen showed a marked reduction in retention when the tank containing the device was pressurized with hydrogen vapor. These tests, however did not indicate any appreciable degradation in retention with helium pressurization or direct heating through the screen. The objective of this article is to determine if the thermocapillary convection arising from phase change in the microscopic pores of such screens could cause these disparities in performance. A numerical model of flow in a single pore suggests that the thermocapillary-induced gradient in liquid pressure along the surface can strongly affect surface morphology. In an evaporative environment, this gradient exerts a stabilizing influence on surface curvature, and preserves the momentum balance between the liquid and gas. With condensation, it causes a force imbalance and a destabilizing suction in the middle of the pore that reduces retention. Results also indicate that introducing an inert gas, such as helium, suppresses this retention loss mechanism by lowering thermocapillary circulation and its associated interfacial pressure gradient.

Schmidt, George R.↗
NASA NTRS1998

Modeling Oxidation Induced Stresses in Thermal Barrier Coatings

The use of thermal barrier coatings (TBC's) in gas turbines has increased dramatically in recent years, due mainly to the need for component protection from ever increasing service temperatures. Oxidation of the bond coat has been identified as an important contributing factor to spallation of the ceramic top coat during service. Additional variables found to influence TBC thermal cycle life include bond coat coefficient of thermal expansion, creep behavior of both the ceramic and bond coat layers, and modulus of elasticity. The purpose of this work was to characterize the effects of oxidation on the stress states within the TBC system, as well as to examine the interaction of oxidation with other factors affecting TBC life.

Ferguson, B. L.↗
NASA NTRS2007

Feasibility Study of Vapor-Mist Phase Reaction Lubrication Using a Thioether Liquid

A primary technology barrier preventing the operation of gas turbine engines and aircraft gearboxes at higher temperatures is the inability of currently used liquid lubricants to survive at the desired operating conditions over an extended time period. Current state-of-the-art organic liquid lubricants rapidly degrade at temperatures above 300 C; hence, another form of lubrication is necessary. Vapor or mist phase reaction lubrication is a unique, alternative technology for high temperature lubrication. The majority of past studies have employed a liquid phosphate ester that was vaporized or misted, and delivered to bearings or gears where the phosphate ester reacted with the metal surfaces generating a solid lubricious film. This method resulted in acceptable operating temperatures suggesting some good lubrication properties, but the continuous reaction between the phosphate ester and the iron surfaces led to wear rates unacceptable for gas turbine engine or aircraft gearbox applications. In this study, an alternative non-phosphate liquid was used to mist phase lubricate a spur gearbox rig operating at 10,000 rpm under highly loaded conditions. After 21 million shaft revolutions of operation the gears exhibited only minor wear.

Morales, Wilfredo↗
NASA NTRS2005

Multilayer Composite Pressure Vessels

A method has been devised to enable the fabrication of lightweight pressure vessels from multilayer composite materials. This method is related to, but not the same as, the method described in gMaking a Metal- Lined Composite-Overwrapped Pressure Vessel h (MFS-31814), NASA Tech Briefs, Vol. 29, No. 3 (March 2005), page 59. The method is flexible in that it poses no major impediment to changes in tank design and is applicable to a wide range of tank sizes. The figure depicts a finished tank fabricated by this method, showing layers added at various stages of the fabrication process. In the first step of the process, a mandrel that defines the size and shape of the interior of the tank is machined from a polyurethane foam or other suitable lightweight tooling material. The mandrel is outfitted with metallic end fittings on a shaft. Each end fitting includes an outer flange that has a small step to accommodate a thin layer of graphite/epoxy or other suitable composite material. The outer surface of the mandrel (but not the fittings) is covered with a suitable release material. The composite material is filament- wound so as to cover the entire surface of the mandrel from the step on one end fitting to the step on the other end fitting. The composite material is then cured in place. The entire workpiece is cut in half in a plane perpendicular to the axis of symmetry at its mid-length point, yielding two composite-material half shells, each containing half of the foam mandrel. The halves of the mandrel are removed from within the composite shells, then the shells are reassembled and bonded together with a belly band of cured composite material. The resulting composite shell becomes a mandrel for the subsequent steps of the fabrication process and remains inside the final tank. The outer surface of the composite shell is covered with a layer of material designed to be impermeable by the pressurized fluid to be contained in the tank. A second step on the outer flange of each end fitting accommodates this layer. Depending on the application, this layer could be, for example, a layer of rubber, a polymer film, or an electrodeposited layer of metal. If the fluid to be contained in the tank is a gas, then the best permeation barrier is electrodeposited metal (typically copper or nickel), which can be effective at a thickness of as little as 0.005 in (.0.13 mm). The electrodeposited metal becomes molecularly bonded to the second step on each metallic end fitting. The permeation-barrier layer is covered with many layers of filament-wound composite material, which could be the same as, or different from, the composite material of the inner shell. Finally, the filament-wound composite material is cured in an ov

DeLay, Tom↗
NASA NTRS2011

Ion-Ice Astrochemistry: Barrierless Low-Energy Deposition Pathways to HCOOH, CH3OH, and CO2 on Icy Grain Mantles from Precursor Cations

A new family of very favorable reaction pathways is explored involving the deposition of ions on icy grain mantles with very low energies. Quantum chemical cluster calculations at the MP2/6-31+G** level in 4H2O clusters and at the B3LYP/6-31+G** level in 17H2O clusters indicate that HCO+ and CH3 + are able to react spontaneously with one of the water molecules in the cluster to form protonated formic acid (HCOOH2 +) and protonated methanol (CH3OH2 +), respectively. It is furthermore found that these initial adducts spontaneously transfer their excess protons to the cluster to form neutral formic acid and methanol, plus solvated hydronium, H3O+. In the final case, if a CO molecule is bound to the surface of the cluster, OH+ may react with it to form protonated carbon dioxide (HCO2 +), which then loses its proton to yield CO2 and H3O+. In the present model, all of these processes were found to occur with no barriers. Discussion includes the analogous gas phase processes, which have been considered in previous studies, as well as the competitive abstraction pathway for HCO(+) + H2O.

Woon, David E.↗
NASA NTRSDate not supplied

Foreign Object Damage in a Yb2Si2O7 Environmental Barrier Coating

Foreign object damage (FOD) is one of the key damage/failure modes in environmental barrier coatings (EBCs) developed for gas turbine engines. A limiting factor of EBC development is the growth of a SiO2 thermally grown oxide (TGO) layer which exacerbates spallation. While there has been extensive research on FOD in metals, ceramics, and ceramic matrix composites (CMCs), there is a limited understanding of the effects of FOD in EBC systems. Previous work studied the effects of TGO growth on FOD in NASA’s Generation II Ytterbium Disilicate EBC. Recently, it has been shown that the addition of oxide modifiers to the Ytterbium Disilicate EBC resulted in significant reduction in TGO growth. The present work will compare FOD in a modified Ytterbium Disilicate EBC to that of the baseline Ytterbium Disilicate EBC. FOD testing was conducted on both as-processed and steam cycled samples at room temperature using a 1.59mm steel ball projectile with particle velocities ranging from 50–300 m/s at a normal incidence angle. The impact damage was characterized by optical profilometry and scanning electron microscopy (SEM) of the cross-sections.

Leland Hoffman↗
NASA NTRS1980

Thermal barrier coatings - Burner rig hot corrosion test results

A Mach 0.3 burner rig test program was conducted to examine the sensitivity of thermal barrier coatings to Na- and V-contaminated combustion gases simulating potential utility gas turbine environments. Coating life of the standard ZrO2-12Y2O3/Ni-16.2Cr-5.6Al-0.6Y (composition in wt %) NASA thermal barrier coating system which was developed for aircraft gas turbines was significantly reduced in such environments. Two thermal barrier coating systems, Ca2SiO4/Ni-16.2Cr-5.6Al-0.6Y and ZrO2-8Y2O3/Ni-16.4Cr-5.1Al-0.15Y and a less insulative cermet coating system, 50 vol % MgO-50 vol % Ni-19.6Cr-17.1Al-0.97Y/Ni-16.2Cr-5.6Al-0.6Y, were identified as having much improved corrosion resistance compared to the standard coating.

Hodge, P. E.↗
NASA NTRS1994

Heat Pipe With Interrupted Slot

Newer version of heat pipe slot interrupted by plug or, if heat pipe is cast, by bridge of heat-pipe material cast integrally across groove. Small barrier assists in priming heat pipe. Vapor and noncondensible gas still accumulates in liquid channel at evaporator before or during startup, but barrier keeps liquid out of small part of slot at bubble. Dry part of slot allows bubble to escape into vapor channel, making room for liquid to move in during startup.

Brown, Richard F.↗
NASA NTRS1994

A facility to produce an energetic, ground state atomic oxygen beam for the simulation of the Low-Earth Orbit environment

Because of the continuing commitment to activity in low-Earth orbit (LEO), a facility is under development to produce energetic atmospheric species, particularly atomic oxygen, with energies ranging from 5 to 80 eV. This relatively high flux facility incorporates an ion engine to produce the corresponding specie ion which is charge exchanged to produce a neutral atomic beam. Ion fluxes of around 10(exp 15) sec(exp -1) with energies of 20-70 eV have been achieved. A geometrically augmented inertially tethered charge exchanger (GAITCE) was designed to provide a large column depth of charge exchange gas while reducing the gas load to the low pressure portion of the atomic beam facility. This is accomplished using opposed containment jets which act as collisional barriers to the escape of the dense gas region formed between the jets. Leak rate gains to the pumping system on the order of 10 were achieved for moderate jet mass flows. This system provides an attractive means for the charge exchange of atomic ions with a variety of gases to produce energetic atomic beams.

Ketsdever, Andrew D.↗
NASA NTRS1979

Metallic thermal seal

Thermal barrier, constructed of U-shaped metal strips and room temperature-vulcanized silicon rubber, prevents hot gas from escaping through gaps. In application metallic barrier could be used to prevent heat from escaping through gaps around door, windows, partitions, and similar structures.

Bellavia, J.↗
NASA NTRS2008

Thermal and Environmental Barrier Coating Development for Advanced Propulsion Engine Systems

Ceramic thermal and environmental barrier coatings (TEBCs) are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments, and extend component lifetimes. Advanced TEBCs that have significantly lower thermal conductivity, better thermal stability and higher toughness than current coatings will be beneficial for future low emission and high performance propulsion engine systems. In this paper, ceramic coating design and testing considerations will be described for turbine engine high temperature and high-heat-flux applications. Thermal barrier coatings for metallic turbine airfoils and thermal/environmental barrier coatings for SiC/SiC ceramic matrix composite (CMC) components for future supersonic aircraft propulsion engines will be emphasized. Further coating capability and durability improvements for the engine hot-section component applications can be expected by utilizing advanced modeling and design tools.

Zhu, Dongming↗
NASA NTRS2011

Composite Overwrapped Pressure Vessels, A Primer

Due to the extensive amount of detailed information that has been published on composite overwrapped pressure vessels (COPVs), this document has been written to serve as a primer for those who desire an elementary knowledge of COPVs and the factors affecting composite safety. In this application, the word "composite" simply refers to a matrix of continuous fibers contained within a resin and wrapped over a pressure barrier to form a vessel for gas or liquid containment. COPVs are currently used at NASA to contain high pressure fluids in propulsion, science experiments, and life support applications. They have a significant weight advantage over all metal vessels but require unique design, manufacturing, and test requirements. COPVs also involve a much more complex mechanical understanding due to the interplay between the composite overwrap and the inner liner. A metallic liner is typically used in a COPV as a fluid permeation barrier. The liner design concepts and requirements have been borrowed from all-metal vessels. However, application of metallic vessel design standards to a very thin liner is not straightforward. Different failure modes exist for COPVs than for all-metal vessels, and understanding of these failure modes is at a much more rudimentary level than for metal vessels.

McLaughlan, Pat B.↗
NASA NTRS1993

Thermal Barrier Coatings

In order to reduce heat transfer between a hot gas heat source and a metallic engine component, a thermal insulating layer of material is placed between them. This thermal barrier coating is applied by plasma spray processing the thin films. The coating has been successfully employed in aerospace applications for many years. Lewis Research Center, a leader in the development engine components coating technology, has assisted Caterpillar, Inc. in applying ceramic thermal barrier coatings on engines. Because these large engines use heavy fuels containing vanadium, engine valve life is sharply decreased. The barrier coating controls temperatures, extends valve life and reduces operating cost. Additional applications are currently under development.

Source record↗
NASA NTRS1988

Thermal analysis of thermal barrier coatings in a high heat flux environment

Gas temperatures and pressures were measured around the second test position in the H2/O2 rocket engine at NASA-Lewis. Measured gas temperatures generally varied from 1210 to 1390 C. Measured pressures were in good agreement with other studies for throat tubes in a square chamber rocket engine. Heat transfer coefficients were measured at 90 and 180 degrees from the stagnation point and resulted in values of 27.5 and 8.5 kW/sq m C, respectively. A thermal model was developed to predict temperatures in bare and coated tubes and rods. Agreement between measured and predicted temperatures below the surface of a bare Mar-M 246 tube was very good for most of the heat up and cool down period. Predicted temperatures were significantly below measured temperatures for the coated tubes. A thermal model to simulate heat transfer to the leading edge of an HPFTP blade was developed and showed that TBCs can significantly dampen the thermal transient which occurs in the HPFTP during the startup of the SSME.

Nesbitt, James A.↗